Fill port for a balloon

ABSTRACT

A system for filling balloons with lift gas is provided. The system includes apparatus for use with a balloon envelope of a balloon. This apparatus includes a main body having first and second portions. The first portion has a fill port and a hollow tube portion in communication with the fill port. The second portion has a surface and is insertable into a predefined opening in the balloon envelope. The surface of the second portion is configured to attach to an inner portion of the balloon envelope when the second portion is inserted in the predefined opening.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 14/546,144, filed Nov. 18, 2014, the disclosure of which isincorporated herein by reference.

BACKGROUND

Computing devices such as personal computers, laptop computers, tabletcomputers, cellular phones, and countless types of Internet-capabledevices are increasingly prevalent in numerous aspects of modem life. Assuch, the demand for data connectivity via the Internet, cellular datanetworks, and other such networks, is growing. However, there are manyareas of the world where data connectivity is still unavailable, or ifavailable, is unreliable and/or costly. Accordingly, additional networkinfrastructure is desirable.

Some systems may provide network access via a balloon network operatingin the stratosphere. Because of the various forces experienced by theseballoons during deployment and operation, there is a balancing of needsbetween flexibility and stability of materials. The balloons may be madeof an envelope material configured in sections or lobes to create a“pumpkin” or lobed balloon. The lobes are supported by a plurality oftendons.

Before a balloon can be deployed, the balloon envelope must be inflatedwith lighter than air lift gases, such as helium, hydrogen or othertypes of gases. As an example, an interface, such as a small fill tube,may be attached to a top plate on the balloon and coupled to a fillinghose for filling the envelope with gas. However, this interface is oftenprone to leaking and the top plate can sag or can otherwise becomeprolapsed into the balloon, thereby possibly causing damage to theballoon envelope, if there is not sufficient pressure at the top of theballoon to support the plate's weight.

BRIEF SUMMARY

Aspects of the present disclosure are advantageous for providing anapparatus for use with a balloon envelope. In one aspect, the apparatusmay include a main body having first and second portions. The firstportion may have a fill port and a hollow tube portion in communicationwith the fill port. The second portion has a surface and is insertableinto a predefined opening in the balloon envelope. The surface of thesecond portion may be configured to be attached to an inner portion ofthe balloon envelope when the second portion is inserted in thepredefined opening.

In one example, the apparatus further includes a bonding device coupledto the surface of the second portion. The bonding device may beconfigured to cause a portion of the surface to make contact with theinner portion of the balloon envelope in order to bond the two portionstogether. In this regard, the bonding device may include an inflatableballoon disposed within the balloon envelope. This inflatable balloon,when inflated, may be configured to press the portion of surface of thesecond portion against the portion of the balloon envelope. An adhesivemay be disposed on the surface of the second portion to form an airtightseal between the second portion and the balloon envelope.

In another example, the first portion of the apparatus may be configuredto receive one or more tendons for supporting the balloon envelope. Aplurality of threads may be attached to the first portion. These threadsmay be configured to receive a fastener to secure the tendons to theballoon envelope. In that regard, the fastener may be a retaining nutthreadably attached to the first portion.

In yet another example, the second portion may be cylindrically shapedand the first portion may be configured to receive a lift line to liftthe balloon envelope. A cap portion may be attached to the fill port ofthe value body. The cap portion may be configured to seal the fill portso as to prevent lift gas from passing through the hollow tube portion.

In another aspect, a system is provided. The system may include aballoon having a balloon envelope and an apparatus for use with theballoon envelope. The apparatus may include a main body having first andsecond portions. The first portion may have a fill port and a hollowtube portion in communication with the fill port. The second portion hasa surface and is insertable into a predefined opening in the balloonenvelope. The surface of the second portion may be configured to beattached to an inner portion of the balloon envelope when the secondportion is inserted in the predefined opening.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a functional diagram of a system in accordance with aspects ofthe present disclosure.

FIG. 2 is an example of a balloon in accordance with aspects of thepresent disclosure.

FIGS. 3A-3B are example views of an apparatus in accordance with aspectsof the present disclosure.

FIGS. 4A-4C are examples of the apparatus of FIG. 3 positioned relativeto a balloon envelope in accordance with aspects of the presentdisclosure.

FIGS. 5A-5C are examples of a bonding technique in accordance withaspects of the present disclosure.

FIG. 6 is another example of an apparatus in accordance with aspects ofthe present disclosure.

FIG. 7 is a cross-sectional view of the apparatus of FIG. 6 inaccordance with aspects of the present disclosure.

FIGS. 8A-8C are examples of an apparatus coupled to lift line inaccordance with aspects of the present disclosure.

DETAILED DESCRIPTION

The present disclosure generally relates to providing a fill portapparatus for filling balloons with lift gas. In some aspects, theseballoons may include high altitude balloons such as those used incommunication networks. These communication networks may includehundreds of thousands of balloons that are deployed in the stratosphereat the same time. The fill port apparatus may increase the overallefficiency in filling and readying such balloons for deployment.

In one embodiment, the fill port apparatus may include a bell shapedvalve body having first and second portions. The first portion of thevalve body may include a hollow tube and a fill port in communicationwith the hollow tube. The second portion may have a large cylindricallyshaped surface that can be inserted into a predefined opening in a givenballoon envelope. The surface of the valve body may provide the fillport apparatus with a contact area for attaching to the envelopematerial. Hence, the larger this surface is configured, the larger thecontact area. In one example, the valve body may be made of certain typeof flexible material, such as a continuous thermoplastic polymer.

The fill port apparatus may also include a sealing device coupled to thesurface of the valve body. The sealing device may be configured to causethe surface to make contact with the balloon envelope in order to bondthe two together. In one example, the sealing device may include aninflatable balloon disposed within the balloon envelope. An adhesive maybe disposed on the surface of the valve body. When the inflatableballoon is inflated, it may press a portion of the surface of the valvebody onto a portion of the balloon envelope. In this regard, theadhesive may form a seal between the surface of the valve body and theportion of the balloon envelope when the two portions are pressedtogether.

In some examples, the fill port apparatus may further include aplurality of threads attached to the fill port. These threads may beconfigured to receive a lifting device for lifting the balloon envelopeduring assembly or to receive one or more tendons for supporting theballoon envelope.

Aspects, features and advantages of the disclosure will be appreciatedwhen considered with reference to the following description ofembodiments and accompanying figures. The same reference numbers indifferent drawings may identify the same or similar elements.Furthermore, the following description is not limiting; the scope of thepresent technology is defined by the appended claims and equivalents.

Example System

FIG. 1 depicts an example system 100 in which a balloon as describedabove may be used. This example should not be considered as limiting thescope of the disclosure or usefulness of the features of the presentdisclosure. For example, the techniques described herein can be employedon various types of standalone balloons or balloons used with othertypes of systems. In this example, system 100 may be considered a“balloon network.” the system 100 includes a plurality of devices, suchas balloons 102A-F, ground base stations 106 and 112 and links 104, 108,110 and 114 that are used to facilitate intra-balloon communications aswell as communications between the base stations and the balloons. Oneexample of a balloon is discussed in greater detail below with referenceto FIG. 2.

Example Balloon

FIG. 2 is an example balloon 200, which may represent any of theballoons of balloon network 100. As shown, the balloon 200 includes anenvelope 210, a payload 220 and a plurality of tendons 230, 240 and 250attached to the envelope 210.

The balloon envelope 210 may take various forms. In one instance, theballoon envelope 210 may be constructed from materials such aspolyethylene that do not hold much load while the balloon 200 isfloating in the air during flight. Additionally, or alternatively, someor all of envelope 210 may be constructed from a highly flexible latexmaterial or rubber material such as chloroprene. Other materials orcombinations thereof may also be employed. Further, the shape and sizeof the envelope 210 may vary depending upon the particularimplementation. Additionally, the envelope 210 may be filled withvarious gases or mixtures thereof, such as helium, hydrogen or any otherlighter-than-air gas. The envelope 210 is thus arranged to have anassociated upward buoyancy force during deployment of the payload 220.

The payload 220 of balloon 200 may be affixed to the envelope by aconnection 260 such as a cable. The payload 220 may include a computersystem (not shown), having one or more processors and on-board datastorage. The payload 220 may also include various other types ofequipment and systems (not shown) to provide a number of differentfunctions. For example, the payload 220 may include an opticalcommunication system, a navigation system, a positioning system, alighting system, an altitude control system and a power supply to supplypower to various components of balloon 200.

In view of the goal of making the balloon envelope 210 as lightweight aspossible, it may be comprised of a plurality of envelope lobes or goresthat have a thin film, such as polyethylene or polyethyleneterephthalate, which is lightweight, yet has suitable strengthproperties for use as a balloon envelope. In this example, balloonenvelope 210 is comprised of envelope gores 210A-210D.

Pressurized lift gas within the balloon envelope 210 may cause a forceor load to be applied to the balloon 200. In that regard, the tendons230-250 provide strength to the balloon 200 to carry the load created bythe pressurized gas within the balloon envelope 210. In some examples, acage of tendons (not shown) may be created using multiple tendons thatare attached vertically and horizontally. Each tendon may be formed as afiber load tape that is adhered to a respective envelope gore.Alternately, a tubular sleeve may be adhered to the respective envelopeswith the tendon positioned within the tubular sleeve.

Top ends of the tendons 230, 240 and 250 may be coupled together usingan apparatus, such as top cap 201 positioned at the apex of balloonenvelope 210. Bottom ends of the tendons 230, 240 and 250 may also beconnected to one another. For example, a corresponding apparatus, e.g.,bottom cap 220, may be disposed at a base or bottom of the balloonenvelope 210. The top cap 201 at the apex may be the same size and shapeas and bottom cap 220 at the bottom. Both caps include correspondingcomponents for attaching the tendons 230, 240 and 250 to the balloonenvelope 210.

Example Apparatus

As noted above, one aspect of the present technology provides anapparatus to be used as a fill port for a high altitude balloon, such asballoon envelope 210 as described above. FIGS. 3A and 3B illustrate anexample fill port apparatus 300. In FIG. 3A, a side view of theapparatus 300 is shown. In this example, apparatus 300 may include afirst portion 302 and a second portion 304. The first portion 320 ofapparatus 300 includes a fill port 306 for inflation of the balloonenvelope and a hollow tube portion 307 in communication with the fillport 306. The fill port 306 can be coupled to a lift gas fill source(not shown), which can be used to inflate the balloon.

During inflation, the fill port 306 may allow lift gas to pass throughto the hollow tube portion 307 and into an inner portion of theenvelope. The hollow tube portion 307 may thus define a flow channel forthe lift gas to travel and may extend axially through the apparatus 300in order to allow the lift gas to reach the inner portion of theenvelope.

FIG. 3B is a top down view of the apparatus 300. As shown, the secondportion 304 of apparatus 300 may be cylindrically shaped and have aradius that is wider than the radius of the first portion 302. The shapeand size of the second portion 304 may be configured so that theapparatus 300 can make a sufficient amount of contact with the balloonenvelope 210 in order to bond the surface of the second portion 304 witha portion of the balloon envelope material. For example, when theapparatus 300 is attached to the balloon envelope, surface 308 of thesecond portion 304 may make contact with a portion of the balloonenvelope.

Apparatus 300 may be attached to the balloon envelope 210 during themanufacturing process of the balloon 200. For example, before theballoon envelope 210 is completed, the second portion 304 may beinserted into an opening in the balloon envelope, for example, at anapex of the balloon 200. In this regard, the second portion 304 made beof a lightweight yet resistibly flexible material, such as type ofrubber or other types similar material, which can be manipulated andreturn to into an original shape. When the second portion 304 isinserted in the opening of the balloon envelope 210, the surface 306 ofthe second portion 304 can be configured to attach to what will becomean inner portion of the balloon envelope. As noted above, a bonding sealmay be formed between the second portion 304 of the apparatus 300 andthe balloon envelope 210 as discussed in more detail below. This sealmay prevent lift gas from leaking out of the opening of the envelope.

FIGS. 4A-4C are examples 400 of apparatus 300 positioned relative to aballoon envelope 210. With regards to FIG. 4A, the apparatus 300 isshown at an opening 402 in the balloon envelope 210. As shown here, theapparatus 300 is in a first unfolded shape. For example, the secondportion 304 when unfolded may have a cylindrical shape that maycorrespond to a shape of the opening 402 at the apex of the balloonenvelope 210.

The opening 402 in the balloon envelope 210 may be formed in severalways. In one example, the opening 420 can be preconfigured to beincluded at the time the balloon envelope 210 is manufactured. Inanother example, the opening 402 can be created by cutting open aportion of the balloon envelope 210 using any conventional cuttingdevice. Various other techniques can be used to create the opening 402in the balloon envelope 210. The opening 402 may be sized, so that thesecond portion 304 of the apparatus 300 cannot pass through after beingfully inserted into the balloon envelope 210 and unfolded.

Turning to FIG. 4B, the second portion 304 of the apparatus 300 is shownin a partial dashed line as this feature may be located within aninterior 405 of the balloon envelope 210. The second portion 304 of theapparatus 300 may be inserted through opening 402 in the direction ofarrow 405. For example, as shown in FIG. 4B, the second portion 304 canbe folded into a shape that can fit through the opening 402. As notedabove, the second portion 304 may be made of a resistibly flexiblematerial, such as rubber, that can be manipulated then return to anoriginal shape. The second portion 304 is then inserted through theopening 402 and will become a part of the interior of the balloonenvelope 210 when the envelope is completed.

In FIG. 4C, the second portion 304 of apparatus 300 is shown completelydashed line as this portion 304 may be completely located within theinterior 405 of the balloon envelope 210. After insertion of the secondportion 304 through the opening 402, apparatus 300 may return to theoriginal shape. For example, the second portion 304 of the apparatus 300may unfold and extend along contours of the interior 405 of balloonenvelope 210. As shown here, surface 308 of the apparatus 300 may bepositioned below the opening 402 and towards a portion 406 of theinterior 405.

Once the surface 308 of the second portion 304 is positioned below theopening 402, this surface may be bonded to the interior 405 of balloonenvelope 210 as discussed in more detail below. This bond may beconfigured to create a substantially airtight seal between the secondportion 304 and the balloon envelope 210. The airtight seal helpsprevent lift gas from escaping from the opening 402 when balloonenvelope 210 is inflated.

FIGS. 5A-5C illustrates one example of a bonding technique 500, forexample, to create an airtight seal between apparatus 300 and theballoon envelope 210. This is merely one example of a bonding techniqueas other sealing and/or bonding methods may be used to create theairtight seal. In this example, the bonding technique 500 includes usingan inflatable balloon 502 attached to an inflation hose 503 and anadhesive 504, such as type of epoxy. The inflatable balloon 502 may beused to cause a portion of the apparatus 300 to make contact with aninterior 405 of the balloon envelope 210 in order to bond the twoportions together.

As shown in FIG. 5A, the adhesive 504 may be disposed on surface 308 ofapparatus 300. For example, the adhesive 504 may be applied to thesurface 308 before or after the insertion of the second portion 304through opening 402. The inflatable balloon 502 may be then insertedthrough the fill port of the apparatus 300 so that the inflatableballoon 502 may rest within the interior 405 of the balloon envelope210. In this regard, an initial size of the inflatable balloon 502 maybe small enough to pass through the fill port of apparatus 300.

In FIG. 5B, the inflatable balloon 502 is shown slightly inflated. Forexample, upon activation of an air pump (not shown) attached to theinflation hose 503, air may be pumped through the inflation hose 503 ata certain rate that gradually increases the size of the inflatableballoon 502. As the size of the inflatable balloon 502 increases,surface 308 of apparatus 300 may be brought closer to an interior wall406 of the balloon envelope 210, thereby pressing the surface 308 of thesecond portion 304 against a portion of the wall.

In FIG. 5C, the inflatable balloon 502 is shown even more inflated thanin FIG. 5B. Here, the surface 308 of the second portion 304 of apparatus300 is shown in contact with the interior wall 406 of the balloonenvelope 210. As noted above, the adhesive 504 disposed between the twoportions may be used form an airtight seal. For example, the adhesive504 when cured may cause surface 308 to bond with the interior wall 406of the balloon envelope 210. Thereupon, the inflatable balloon 502 maybe deflated and retracted from the interior of the envelope 210 by usingthe inflation hose 503.

Once the apparatus is secured to the balloon envelope, the envelope andballoon may be completed. For example, other components (e.g., tendons)of the balloon may be secured to the balloon envelope 210 to ready theballoon for deployment. The completed balloon may then be inflated usingthe apparatus as discussed above. For example, the completed balloon maybe attached to a lift gas fill source via the fill port of the apparatus300 in order to fill the envelope 210 with lift gas. In some aspects,the apparatus may be used to help secure the other components of theballoon as discussed above in order to produce a completed balloon.These further aspects of the apparatus of the present disclosure arediscussed below.

FIG. 6 is another example of an apparatus 600 for example, to be used asa fill port for a high-altitude balloon. Apparatus 600 may be comparedto the apparatus 300 of FIGS. 3A-3B and thus may be bonded to a balloonenvelope using the bonding technique 500 described above. Similarly,apparatus 600 includes a first portion 602 having a fill port and hollowtube portion (not shown) and a second portion 602 that is attachable toa balloon envelope. The first portion 602 and second portion 604 may becompared to first portion 302 and second portion 304, respectively. Inthis example, the first portion 602 includes a plurality of threads 606.In one example, the threads 606 may be configured to receive a cap 608.The cap 608 may be used to help prevent lift gas from passing throughthe fill port of the apparatus 600. For example, after the balloonenvelope is inflated, the cap 608 may be attached to the threads 606 inorder to help keep the fill port closed.

FIG. 7 is a cross sectional view of the apparatus 600 of FIG. 6. In thisexample, apparatus 600 may be further configured to receive one or moretendons 704. Although only two tendons are shown, any number of tendonsmay be used as needed to complete a balloon such as balloon 200. Thetendons 704 can be looped around the first portion 602 of apparatus 600.In this regard, the first portion 602 may be configured to extend asufficient length outwardly from an apex of the balloon envelope inorder to accommodate the tendons 704. As discussed above, the tendons704 may provide support of supporting a load of lift gas carried by theballoon envelope.

To secure the tendons to apparatus 600, the first portion 602 may beconfigured to receive a fastener 702. The fastener 702 may ensure thatwhen the tendons 704 are placed at the apex they will not fall of theballoon envelope. Fastener 702 may include one or more various differenttypes of clips, nuts, pins or other types of hardware devices. Forexample, the fastener 702 may include a retaining nut. In this example,the retaining nut may be threadably attached to the first portion 602 byusing a twisting motion that may tightly secure the tendons 704 inplace.

In other aspects, apparatus 600 may be configured to receive a liftline. For example, a lifting device (such as a hoist) may be coupled tothe apparatus 600 via the lift line in order to lift the balloonenvelope during assembly. An advantage of using the apparatus 600 tohelp lift the balloon is that may help to eliminate the need to includeadditional attachment features for lifting the balloon envelope.

Turning to FIGS. 8A-8C, an example 800 of an apparatus 810 coupled to alift line 805, is shown. In this example, apparatus 810 may be comparedto apparatus 300 and apparatus 600 and thus may be bonded to a balloonenvelope using the bonding technique 500 described above. Similarlyhere, apparatus 810 includes a first portion 812 having a fill port andhollow tube portion (not shown) and a second portion 814 attached toballoon envelope 210. First portion 812 and second portion 814 may becompared to the first and second portions 302, 304, 602, and 604,respectively.

In FIG. 8A, the balloon envelope 210 is shown coming out of a box 830,such as a shipping box for the envelope 210. As shown, the apparatus 810is attached to an apex of the balloon envelope 210. Here, the balloonenvelope is being pulled upward, for example, by a hoisting device (notshown) using lift line 805. In FIG. 8B, the balloon envelope 210 is evenhigher out of the box 830. And in FIG. 8C, shows the balloon envelope210 at another height. For example, this may be a height high enough toaccommodate the fully inflated balloon envelope 210. At this point, theballoon envelope 210 may be inflated and prepared for deployment.

Most of the foregoing alternative examples are not mutually exclusive,but may be implemented in various combinations to achieve uniqueadvantages. As these and other variations and combinations of thefeatures discussed above can be utilized without departing from thesubject matter defined by the claims, the foregoing description of theembodiments should be taken by way of illustration rather than by way oflimitation of the subject matter defined by the claims. In addition, theprovision of the examples described herein, as well as clauses phrasedas “such as,” “including” and the like, should not be interpreted aslimiting the subject matter of the claims to the specific examples;rather, the examples are intended to illustrate only one of manypossible embodiments. Further, the same reference numbers in differentdrawings can identify the same or similar elements.

The invention claimed is:
 1. A method of manufacturing a balloonincluding a balloon envelope, the method comprising: folding a secondportion of a fill port apparatus having a first portion including a fillport and the second portion; inserting at least a portion of the foldedsecond portion through an opening in balloon envelope material, whereinthe opening is arranged at a location of the balloon envelope materialcorresponding to an apex of the balloon envelope; unfolding the foldedsecond portion when the at least a portion is through the opening; afterthe unfolding, securing the at least a portion to a surface of theballoon envelope material; after the securing, inflating the balloonenvelope with lift gas though the fill port of the apparatus; and afterthe inflating, attaching a cap to the fill port of the apparatus.
 2. Themethod of claim 1, further comprising forming the opening in the balloonenvelope material by cutting the balloon envelope material.
 3. Themethod of claim 2, wherein the second portion has a cylindrical shapeand the opening has a shape corresponding to the cylindrical shape. 4.The method of claim 1, wherein the opening is sized such that the secondportion of the apparatus cannot pass through the opening after theinserting when the second portion is unfolded.
 5. The method of claim 1,wherein the second portion is comprised of a material that allows thesecond portion to return to a pre-folded shape after the folding,wherein prior to the folding, the second portion is in the pre-foldedshape and the unfolding allows the second portion to return to thepre-folded shape.
 6. The method of claim 1, wherein the at least aportion is inserted such that the at least a portion is arranged at alocation corresponding to an interior of the balloon envelope.
 7. Themethod of claim 1, wherein the unfolding allows the second portion toextend along contours of the balloon envelope material corresponding toan interior of the balloon envelope.
 8. The method of claim 1, whereinafter the unfolding, a top surface of the at least a portion is orientedtowards a surface of the balloon envelope material corresponding to aninterior of the balloon envelope.
 9. The method of claim 1, wherein thesecuring includes bonding the at least a portion to the balloon envelopematerial in order to create a seal.
 10. The method of claim 9, whereinthe securing includes applying an adhesive to create the seal.
 11. Themethod of claim 10, wherein the adhesive is applied prior to theinserting.
 12. The method of claim 10, wherein the adhesive is appliedafter the inserting.
 13. The method of claim 10, further comprising:placing an inflatable balloon through the fill port; and after theplacing, inflating the inflatable balloon with gas to cause the at leasta portion to press the adhesive against the balloon envelope material inorder to create the seal.
 14. The method of claim 13, furthercomprising, after the inflating, deflating the inflatable balloon. 15.The method of claim 14, further comprising pulling the deflatedinflatable balloon through the fill port.
 16. The method of claim 10,wherein the seal is configured to be airtight when the balloon is inflight in the stratosphere.
 17. The method of claim 1, wherein attachingthe cap includes screwing the cap onto the fill port using complementarythreading of the cap and fill port.
 18. The method of claim 1, furthercomprising, after the securing, attaching a set of tendons to the fillport apparatus.